SAFETY-03: alarm when a computed setpoint exceeds the rating, do not just clip it
The clamp was never the missing half. specs.md 10.3 records an unclamped integrator climbing ~130 W per 4 s past 10 kW and reporting 14 768 W pinned at the 5 kW rail; clipped silently that is a flat, legal-looking 5000 W hold and nothing says the loop asked for three times it. write_setpoint() - the one path every write takes - now clamps to the VALIDATED max_w and reports whether the raw value differed; check_output_clamp() raises OUTPUT_CLAMP as a notification, an ERROR, an event row and a red status banner. Not a trip: the clamped value is written and the loop keeps running. The rating is max_w and nothing is min()ed at runtime - CFG-01 already refuses a max_w outside the device range at startup. The device range is applied second as defence in depth; it cannot bite after a successful validation, so if it ever does it alarms too and names the bound. No new config key. Decision grew i_clamped / clamped booleans, and that is the load-bearing part: `reason` is one string that slew-limiting and the saturation freeze overwrite, so an alarm keyed on it is silent on exactly the cycles a winding loop produces. Mutating main.py back onto the string drops the 10.3 replay from 2 engagements to 0. Distinct from saturation by construction - no shared reason code, notification id, status row or counter - and checked in the negative, after first asserting the saturation freeze really did engage. Two things found by running it rather than by reading it: a row per engagement flushed the 40-row event log and evicted SAFETY-18's own METER FROZEN? row (now coalesced per episode with an exact count), and a naive clamp turns a nan into a command at the full rating because every comparison against nan is False. test_clamp.py is new: assert-based, no framework. Six author mutations reproduced red, including "clamp kept, alarm deleted". Two of the check's own hypotheses about the freeze/clamp interaction were refused by its sweep and rewritten to what it measured. Co-Authored-By: Claude Opus 5 <noreply@anthropic.com> Claude-Session: https://claude.ai/code/session_015VXjA3LWccN1rJsk3okyPC
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Claude Opus 5
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@@ -64,6 +64,23 @@ class Decision:
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# and quantisation. Carry it back in as `i_w` next cycle; that is what keeps
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# it a separate quantity from the command.
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i_w: float = 0.0
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# SAFETY-03. Did a clamp actually engage this cycle - i.e. did the RAW
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# computed value differ from the bounded one?
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#
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# ⚠️ THESE EXIST BECAUSE `reason` CANNOT ANSWER THAT QUESTION. `reason` is
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# one string and every later stage overwrites it: a cycle that clamps the
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# integrator and is then slew limited reports "slew-limited", and one that
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# clamps while saturated reports "saturated-freeze". Both ARE the winding
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# case, and on the string the clamp signal is gone before anything can alarm
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# on it. These two are written where the clamp happens and are never
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# overwritten, so they mean exactly what they say and nothing else.
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#
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# `i_clamped` is the one that fires on a default install: the integrator
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# bound is reached first, so `clamped` is unreachable unless
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# `integrator_max_w` is deliberately set above `max_w`. Alarm on BOTH - see
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# the comment at the bound below, and clamp.py.
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i_clamped: bool = False
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clamped: bool = False
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def compute(
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@@ -188,7 +205,8 @@ def compute(
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# bound is not. It is what makes the worst-case unwind time finite and
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# knowable instead of a function of how long the error happened to stand.
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bounded = max(-limit, min(limit, i_w))
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if bounded != i_w:
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i_clamped = bounded != i_w
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if i_clamped:
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# ⚠️ SAFETY-03 (alarm whenever the loop winds into a rail) must watch
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# for THIS, not for "clamped" below. At the default limit == max_w the
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# integrator bound is reached first and the command derived from it can
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@@ -209,7 +227,8 @@ def compute(
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# --- ORDER MATTERS: clamp -> slew -> freeze ----------------------------
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# An early draft applied a floor after the clamp and let demand escape it.
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target = max(-tuning.max_w, min(tuning.max_w, want))
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if target != want:
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clamped = target != want
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if clamped:
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reason = "clamped"
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slewed = max(prev_w - tuning.slew_w, min(prev_w + tuning.slew_w, target))
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@@ -235,7 +254,8 @@ def compute(
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step = max(1, int(tuning.step_w))
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target = round(target / step) * step
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return Decision(float(target), sat_count, frozen, reason, float(i_w))
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return Decision(float(target), sat_count, frozen, reason, float(i_w),
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i_clamped, clamped)
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def maintenance_charge_floor(
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